U.S. patent application number 17/089526 was filed with the patent office on 2022-05-05 for flexure arrangements for optical components.
The applicant listed for this patent is COGNEX CORPORATION. Invention is credited to John Filhaber.
Application Number | 20220137426 17/089526 |
Document ID | / |
Family ID | |
Filed Date | 2022-05-05 |
United States Patent
Application |
20220137426 |
Kind Code |
A1 |
Filhaber; John |
May 5, 2022 |
FLEXURE ARRANGEMENTS FOR OPTICAL COMPONENTS
Abstract
An optical system can include a receiver secured to a first
optical component and a flexure arrangement secured to a second
optical component. The flexure arrangement can include a plurality
of flexures, each with a free end that can extend away from the
second optical component and into a corresponding cavity of the
receiver. Each of the cavities can be sized to receive adhesive
that secures the corresponding flexure within the cavity when the
adhesive has hardened, and to permit adjustment of the
corresponding flexure within the cavity, before the adhesive has
hardened, to adjust an alignment of the first and second optical
components relative to multiple degrees of freedom.
Inventors: |
Filhaber; John; (East
Haddam, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COGNEX CORPORATION |
Natick |
MA |
US |
|
|
Appl. No.: |
17/089526 |
Filed: |
November 4, 2020 |
International
Class: |
G02B 27/62 20060101
G02B027/62 |
Claims
1. An optical system comprising: a receiver that includes a
receiver body secured to a first optical component, the receiver
further including a first pocket block, a second pocket block, and
a third pocket block that extend from the receiver body and include
a first pocket, a second pocket, and a third pocket, respectively;
and a flexure arrangement that includes a flexure base secured to a
second optical component, the flexure arrangement further including
a first flexure, a second flexure, and a third flexure that extend
from the flexure base into the first, second, and third pockets,
respectively, and are secured therein with adhesive; each of the
first, second, and third pockets being sized to permit adjustment
of the corresponding first, second, or third flexure within the
pocket along multiple axes before the adhesive has hardened, to
adjust an alignment of the first and second optical components
relative to multiple degrees of freedom.
2. The optical system of claim 1, wherein the first, second, and
third flexures extend substantially perpendicularly from the
flexure base and the first, second, and third pocket blocks extend
substantially perpendicularly from the receiver body.
3. The optical system of claim 1, wherein each of the first,
second, and third pockets has an elongate cross-section
perpendicular to an insertion direction for the first, second, and
third flexures, respectively, that is configured to adjustably
receive a planar portion of the corresponding first, second, or
third flexure.
4. The optical system of claim 3, wherein a well is formed within
each of the first, second, and third pockets, sized to receive
adhesive to provide at least a minimum bond line thickness for the
adhesive, to secure the corresponding first, second, or third
flexure.
5. The optical system of claim 4, further comprising at least one
of: an injection port in fluid communication with at least one of
the first, second, or third pockets; and an opening directed
through at least one of the first, second, or third flexures that
corresponds with the at least one of the first, second, or third
pockets; wherein the injection port, the opening, and the well are
aligned for passage of adhesive from the injection port, through
the opening, to the well.
6. An optical system comprising: a receiver secured to a first
optical component, the receiver including a receiver body that
supports the first optical component and a plurality of slots; and
a flexure arrangement secured to a second optical component, the
flexure arrangement including a plurality of flexures, each with a
free end that extends away from the second optical component and
into a corresponding one of the slots; each of the slots being
sized to receive adhesive that secures the corresponding flexure
within the slot when the adhesive has hardened, and to permit
adjustment of the corresponding flexure within the slot, before the
adhesive has hardened, to adjust an alignment of the first and
second optical components relative to multiple degrees of
freedom.
7. The optical system of claim 6, wherein the flexure arrangement
includes a flexure base with a plurality of second slots; wherein
each flexure includes a second free end that extends into a
corresponding one of the second slots; and wherein each of the
second slots is sized to receive adhesive that secures the
corresponding flexure within the slot when the adhesive has
hardened, and to permit adjustment of the corresponding flexure
within the slot, before the adhesive has hardened, to adjust an
alignment of the first and second optical components relative to
multiple degrees of freedom.
8. The optical system of claim 6, wherein an internal side wall of
at least one of the slots includes one or more of: a well that
receives adhesive to provide a predetermined minimum bond line
thickness for the corresponding flexure within which the
corresponding flexure is nested when received in the at least one
of the slots; or a recess within which the corresponding at least
one flexure is nested when received in the at least one of the
slots.
9. The optical system of claim 6, wherein the receiver body and the
plurality of protrusions are integrally formed.
10. The optical system of claim 9, wherein the receiver includes a
plurality of protrusions extending from the receiver body; and
wherein the slots are formed as pockets extending into the
protrusions.
11. The optical system of claim 10, wherein at least one of the
slots is formed as a pocket at least partly defined by a wall
member that is secured to the receiver body at the corresponding
protrusion.
12. The optical system of claim 6, wherein the open ends of the
slots open away from receiver body.
13. The optical system of claim 6, wherein the flexure arrangement
includes a flexure base that is integrally formed with the
flexures, the flexure base supporting the second optical
component.
14. The optical system of claim 6, wherein at least one of the
flexures is a planar flexure.
15. The optical system of claim 14, wherein at least one of the
slots, corresponding to the at least one of the flexures, has an
elongate cross-section corresponding to an elongate cross-section
of the planar flexure.
16. The optical system of claim 15, wherein the receiver is a first
receiver, and the plurality of slots is a first plurality of slots,
and the free ends of the flexures are first free ends; wherein the
optical system further comprises a second receiver including a
second plurality of holes; and wherein each slot of the second
plurality of slots receives a second free end of a corresponding
one of the flexures, opposite the first free end, and is sized to
receive adhesive that secures the corresponding flexure within the
slot when the adhesive has hardened.
17. The optical system of claim 6, wherein the at least one of the
slots defines a pocket that fully surrounds a perimeter of the
corresponding flexure.
18. The optical system of claim 17, wherein a first opening is
included on one or more of (i) at least one protrusion on the
receiver that corresponds to the at least one of the slots or (ii)
at least one of the flexures, the first opening being separate from
the open end of the pocket and configured to receive the adhesive
during introduction of the adhesive into the pocket.
19. The optical system of claim 18, wherein the at least one of the
protrusions further includes a second opening, separate from the
first opening and the open end of the pocket, to provide visual
access to the adhesive within the pocket.
20. An optical system comprising: a receiver secured to a first
optical component, the receiver including a receiver body that
supports the first optical component, and a plurality of cavities;
a flexure arrangement secured to a second optical component, the
flexure arrangement including a plurality of flexures that extend
away from the second optical component to be nested within the
cavities; each of the cavities: including adhesive that is hardened
to secure the corresponding flexure within the cavity; and having a
cross-section that is larger than a cross-section of the
corresponding flexure and a depth in an insertion direction that is
larger than an insertion length for the corresponding flexure, so
that the corresponding flexure is adjustable relative to multiple
degrees of freedom within the cavity, while remaining nested within
the cavity, before the adhesive is hardened.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
BACKGROUND
[0003] Flexures have been utilized in optical systems to provide
varying degrees of stability and movement for optical components
within the specific optical system. For example, flexures can
provide a resilient interface between the optical components
coupled thereto, providing advantages for the optical system
including absorption of transient stresses to adjustments in
orientation for the optical component coupled thereto.
SUMMARY
[0004] Some embodiments of the disclosure provide an optical
system. The optical system can include a receiver that can include
a receiver body secured to a first optical component. The receiver
can further include a first pocket block, a second pocket block,
and a third pocket block that extend from the receiver body and can
include a first pocket, a second pocket, and a third pocket,
respectively. The optical system can include a flexure arrangement
that can include a flexure base secured to a second optical
component. The flexure arrangement can further include a first
flexure, a second flexure, and a third flexure that extend from the
flexure base into the first, second, and third pockets,
respectively, and are secured therein with adhesive. Each of the
first, second, and third pockets can be sized to permit adjustment
of the corresponding first, second, or third flexure within the
pocket along multiple axes before the adhesive has hardened or
prior to insertion of the adhesive, to adjust an alignment of the
first and second optical components relative to multiple degrees of
freedom.
[0005] Some embodiments of the disclosure provide an optical
system. The optical system can include a receiver secured to a
first optical component. The receiver can include a receiver body
that supports the first optical component and a plurality of slots.
The optical system can include a flexure arrangement secured to a
second optical component. The flexure arrangement can include a
plurality of flexures, each with a free end that can extend away
from the second optical component and into a corresponding one of
the slots. Each of the slots can be sized to receive adhesive that
secures the corresponding flexure within the slot when the adhesive
has hardened, and to permit adjustment of the corresponding flexure
within the slot, before the adhesive has hardened, to adjust an
alignment of the first and second optical components relative to
multiple degrees of freedom.
[0006] Some embodiments of the disclosure can provide an optical
system. The optical system can include a receiver secured to a
first optical component. The receiver can include a receiver body
that supports the first optical component, and a plurality of
cavities. The optical system can include a flexure arrangement
secured to a second optical component. The flexure arrangement can
include a plurality of flexures that extend away from the second
optical component to be nested within the cavities. Each of the
cavities can include adhesive that is hardened to secure the
corresponding flexure within the cavity. Each of the cavities can
have a cross-section that is larger than a cross-section of the
corresponding flexure and a depth in an insertion direction that is
larger than an insertion length for the corresponding flexure, so
that the corresponding flexure is adjustable relative to multiple
degrees of freedom within the cavity, while remaining nested within
the cavity, before the adhesive is hardened.
[0007] In some embodiments, one or more flexures can extend
substantially perpendicularly from a flexure base.
[0008] In some embodiments, one or more pocket blocks (or other
protrusions) can extend substantially perpendicularly from a
receiver body. One or more cavities to receive a corresponding
flexure can be formed in the one or more pocket blocks (or other
protrusions).
[0009] In some embodiments, one or more (e.g., each) pocket or
other cavity can have an elongate cross-section perpendicular to an
insertion direction for a corresponding flexure. A cross-section
can be configured to adjustably receive a planar portion of the
corresponding flexure or can otherwise correspond to a
cross-section (e.g., an elongate cross-section) of a flexure.
[0010] In some embodiments, a well can be formed within one or more
pockets or other cavities, sized to receive adhesive to provide at
least a minimum bond line thickness for the adhesive, to secure a
corresponding flexure. In some embodiments, a well can be formed on
a side wall of a pocket (or other cavity).
[0011] In some embodiments, an injection port can be in fluid
communication with at least one pocket. An opening can be directed
through at least one a flexure that corresponds with the at least
one pocket. The injection port, the opening, and a well of the
pocket can be aligned (e.g., along an axis defined by the injection
port) for passage of adhesive from the injection port, through the
opening, to the well.
[0012] In some embodiments, a flexure arrangement can include a
flexure base with one or more base slots (or other cavities). A
free end of one or more corresponding flexures can extend into a
corresponding one of the base slots (or other cavities) to be
secured to the flexure base. The one or more base slots (or other
cavities) can be sized to receive adhesive that secures the
corresponding flexure to the flexure base. Additionally or
alternatively, the one or more base slots (or other cavities) can
be sized to permit adjustment of the corresponding flexure with
multiple degrees of freedom.
[0013] In some embodiments, a side wall of a cavity can include a
recess, within which a corresponding flexure can be nested when
received in the cavity.
[0014] In some embodiments, a receiver body and one or more
protrusions with corresponding cavities can be integrally formed.
In some embodiments, a flexure and a flexure base can be integrally
formed. In some embodiments a flexure base or receiver body can be
an integral part of an optical component.
[0015] In some embodiments, a receiver can include a plurality of
protrusions, with slots formed as pockets that extend into the
protrusions.
[0016] In some embodiments, a pocket can be at least partly defined
by a wall member that is secured to the receiver body at the
corresponding protrusion.
[0017] In some embodiments, an open end of a slot or other cavity
can open away from a receiver body (i.e., can be configured to
receive a component that is moved toward the receiver body).
[0018] In some embodiments, at least one flexure can be a planar
flexure.
[0019] In some embodiments, a receiver can be a first receiver, and
a plurality of holes can be a first plurality of holes. The optical
system can include a second receiver including a second plurality
of holes. The second plurality of holes can be configured to each
receive an opposing free end of each flexure of the plurality of
flexures.
[0020] In some embodiments, a slot can define a pocket that fully
surrounds a perimeter of a corresponding flexure.
[0021] In some embodiments, an opening can be included within a
receiver, separate from an open end of a cavity, and can be
configured to receive the adhesive during introduction of the
adhesive into the cavity. In some embodiments, an opening can be
included on a flexure and can be configured to receive the adhesive
during introduction of the adhesive into the cavity. In some
embodiments, openings on a flexure and a receiver, to receive
adhesive, can be aligned when the flexure is received in a cavity
of the receiver.
[0022] In some embodiments, a receiver can include another opening,
separate from the open end of a cavity, to provide visual access to
the adhesive within the pocket (e.g., to inspect for appropriate
distribution of the adhesive).
[0023] Some embodiments of the disclosure can provide a method of
aligning a first component and a second component of an optical
system. The method can include inserting, into a plurality of
cavities of a receiver that supports the first component, a
plurality of flexures of a flexure arrangement that supports the
second component. The method can include with the flexures
remaining within the cavities, adjusting a collective positioning
of the flexures relative to the cavities to adjust an alignment of
the first and second components with to each other, relative to a
plurality of degrees of freedom. The method can include introducing
a first amount of adhesive into the cavities, and while maintaining
the adjusted collective positioning of the flexures, curing the
first amount of adhesive to fix the flexures within the cavities
with the adjusted collective positioning.
[0024] In some embodiments, the method can include hardening a
second amount of adhesive exterior to cavities prior to curing a
first amount of adhesive to maintain flexures within the cavities
with an adjusted collective positioning.
[0025] In some embodiments, a first amount of adhesive can be
introduced into cavities via first openings into the cavities. The
method can include verifying an introduction of the first amount of
adhesive via second openings into the cavities that are different
from the first openings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings, which are incorporated in and
form a part of this specification, illustrate embodiments of the
disclosure and, together with the description, serve to explain the
principles of embodiments of the disclosure.
[0027] FIG. 1 shows a schematic illustration of an optical system
according to some embodiments of the disclosure.
[0028] FIG. 2A shows a schematic illustration of an assembly
according to some embodiments of the disclosure.
[0029] FIG. 2B is a cross-sectional view of the assembly of FIG. 2A
taken along line 2B-2B of FIG. 2A.
[0030] FIG. 2C shows a schematic illustration of another assembly
according to some embodiments of the disclosure.
[0031] FIG. 2D is a cross-sectional view of the assembly of FIG. 2C
taken along line 2D-2D of FIG. 2C.
[0032] FIG. 2E shows a schematic illustration of another assembly
according to some embodiments of the disclosure.
[0033] FIG. 2F is a cross-sectional view of the assembly of FIG. 2E
taken along line 2F-2F of FIG. 2E.
[0034] FIG. 2G shows a schematic illustration of another assembly
according to some embodiments of the disclosure.
[0035] FIG. 2H is a cross-sectional view of the assembly of FIG. 2G
taken along line 2H-2H of FIG. 2G.
[0036] FIG. 3 shows a top isometric view of an optical system.
[0037] FIG. 4 shows a bottom isometric view of the optical system
of FIG. 3.
[0038] FIG. 5 shows a bottom plan view of the optical system of
FIG. 3.
[0039] FIG. 6 shows a front isometric view of an optical
system.
[0040] FIG. 7 shows a front isometric view of a flexure arrangement
and a receiver of the optical system of FIG. 6.
[0041] FIG. 8 shows a cross-sectional view of a pocket of the
receiver of FIG. 7, with a flexure therein, taken along line 8-8 of
FIG. 7.
[0042] FIG. 9 shows another cross-sectional view of the pocket with
the flexure therein of the arrangement of FIG. 7, taken along line
9-9 of FIG. 7.
[0043] FIG. 10 shows an exploded view of the assembly of FIG. 7
defined by the flexure arrangement and the receiver.
[0044] FIG. 11 is a bottom plan view of the receiver of the optical
system of FIG. 6.
[0045] FIG. 12 is a front isometric view of the interior space of
the pocket block of the receiver of FIG. 6.
[0046] FIG. 13 is a front isometric view of the interior space of
the block cap of the receiver of FIG. 6.
[0047] FIG. 14 shows a flowchart of a process for assembling an
optical system.
DETAILED DESCRIPTION
[0048] Before any embodiments of the disclosure are explained in
detail, it is to be understood that the many embodiments of the
disclosure are not limited in their application to the details of
construction and the arrangement of components set forth in the
following description or illustrated in the following drawings and
can be practiced in various ways. Also, it is to be understood that
the phraseology and terminology used herein is for the purpose of
description and should not be regarded as limiting. The use of
"including," "comprising," or "having" and variations thereof
herein is meant to encompass the items listed thereafter and
equivalents thereof as well as additional items. Unless specified
or limited otherwise, the terms "secured," "mounted," "connected,"
"supported," and "coupled" and variations thereof are used broadly
and encompass both direct and indirect mountings, connections,
supports, and couplings. Further, "secured," "connected," and
"coupled" are not restricted to physical or mechanical connections
or couplings.
[0049] As used herein, unless otherwise defined or limited, ordinal
numbers are used herein for convenience of reference based
generally on the order in which particular components are presented
for the relevant part of the disclosure. In this regard, for
example, designations such as "first," "second," etc., generally
indicate only the order in which the relevant component is
introduced for discussion and generally do not indicate or require
a particular spatial arrangement, functional or structural primacy
or order.
[0050] As used herein, unless otherwise defined or limited,
directional terms are used for convenience of reference for
discussion of particular figures or examples. For example,
references to downward (or other) directions or front (or other)
positions may be used to discuss aspects of a particular example or
figure, but do not necessarily require similar orientation or
geometry in all installations or configurations. Correspondingly,
for example, a "top" feature as described may sometimes be disposed
below a "bottom" feature as described (and so on), in some
arrangements or embodiments. Further, references to particular
rotational or other movements (e.g., counterclockwise rotation) is
generally intended as a description only of movement relative a
reference frame of a particular example of illustration.
[0051] In some embodiments, aspects of the disclosure, including
computerized implementations of methods according to the
disclosure, can be implemented as a system, method, apparatus, or
article of manufacture using standard programming or engineering
techniques to produce software, firmware, hardware, or any
combination thereof to control a processor device (e.g., a serial
or parallel general-purpose or specialized processor chip, a
single- or multi-core chip, a microprocessor, a field programmable
gate array, any variety of combinations of a control unit,
arithmetic logic unit, and processor register, and so on), a
computer (e.g., a processor device operatively coupled to a
memory), or another electronically operated controller to implement
aspects detailed herein. Accordingly, for example, embodiments of
the disclosure can be implemented as a set of instructions,
tangibly embodied on a non-transitory computer-readable media, such
that a processor device can implement the instructions based upon
reading the instructions from the computer-readable media. Some
embodiments of the disclosure can include (or utilize) a control
device such as an automation device, a special purpose or
general-purpose computer including various computer hardware,
software, firmware, and so on, consistent with the discussion
below. As specific examples, a control device can include a
processor, a microcontroller, a field-programmable gate array, a
programmable logic controller, logic gates, etc., and other typical
components that are known in the art for implementation of
appropriate functionality (e.g., memory, communication systems,
power sources, user interfaces and other inputs, etc.).
[0052] The term "article of manufacture" as used herein is intended
to encompass a computer program accessible from any
computer-readable device, carrier (e.g., non-transitory signals),
or media (e.g., non-transitory media). For example,
computer-readable media can include but are not limited to magnetic
storage devices (e.g., hard disk, floppy disk, magnetic strips, and
so on), optical disks (e.g., compact disk (CD), digital versatile
disk (DVD), and so on), smart cards, and flash memory devices
(e.g., card, stick, and so on). Additionally it should be
appreciated that a carrier wave can be employed to carry
computer-readable electronic data such as those used in
transmitting and receiving electronic mail or in accessing a
network such as the Internet or a local area network (LAN). Those
skilled in the art will recognize that many modifications may be
made to these configurations without departing from the scope or
spirit of the claimed subject matter.
[0053] Certain operations of methods according to the disclosure,
or of systems executing those methods, may be represented
schematically in the FIGS. or otherwise discussed herein. Unless
otherwise specified or limited, representation in the FIGS. of
particular operations in particular spatial order may not
necessarily require those operations to be executed in a particular
sequence corresponding to the particular spatial order.
Correspondingly, certain operations represented in the FIGS., or
otherwise disclosed herein, can be executed in different orders
than are expressly illustrated or described, as appropriate for
particular embodiments of the disclosure. Further, in some
embodiments, certain operations can be executed in parallel,
including by dedicated parallel processing devices, or separate
computing devices configured to interoperate as part of a large
system.
[0054] As used herein in the context of computer implementation,
unless otherwise specified or limited, the terms "component,"
"system," "module," and the like are intended to encompass part or
all of computer-related systems that include hardware, software, a
combination of hardware and software, or software in execution. For
example, a component may be, but is not limited to being, a
processor device, a process being executed (or executable) by a
processor device, an object, an executable, a thread of execution,
a computer program, or a computer. By way of illustration, both an
application running on a computer and the computer can be a
component. One or more components (or system, module, and so on)
may reside within a process or thread of execution, may be
localized on one computer, may be distributed between two or more
computers or other processor devices, or may be included within
another component (or system, module, and so on).
[0055] In some implementations, devices or systems disclosed herein
can be utilized or installed using methods embodying aspects of the
disclosure. Correspondingly, description herein of particular
features, capabilities, or intended purposes of a device or system
is generally intended to inherently include disclosure of a method
of using such features for the intended purposes, a method of
implementing such capabilities, and a method of installing
disclosed (or otherwise known) components to support these purposes
or capabilities. Similarly, unless otherwise indicated or limited,
discussion herein of any method of manufacturing or using a
particular device or system, including installing the device or
system, is intended to inherently include disclosure, as
embodiments of the disclosure, of the utilized features and
implemented capabilities of such device or system.
[0056] The following discussion is presented to enable a person
skilled in the art to make and use embodiments of the disclosure.
Various modifications to the illustrated examples will be readily
apparent to those skilled in the art, and the generic principles
herein can be applied to other examples and applications without
departing from the principles disclosed herein. Thus, embodiments
of the disclosure are not intended to be limited to embodiments
shown, but are to be accorded the widest scope consistent with the
principles and features disclosed herein and the claims below. The
following detailed description is to be read with reference to the
figures, in which like elements in different figures have like
reference numerals. The figures, which are not necessarily to
scale, depict selected examples and are not intended to limit the
scope of the disclosure. Skilled artisans will recognize the
examples provided herein have many useful alternatives and fall
within the scope of the disclosure.
[0057] As briefly described above, flexures for optical systems can
generally provide varying degrees of flexibility and stability for
optical components (e.g., lenses, imaging sensors, projectors or
projector targets, etc.) coupled thereto. The specific flexure
arrangement that supports an optical component (e.g., the number of
flexure arms) can determine how the optical component can move
within the optical system. For example, flexure arrangements
generally provide a structure that can locally absorb stresses and
reliably dissipate those local stresses to return the optical
component to its starting (or initial) position. In other words,
flexure arrangements can provide a structure that repeatedly
returns an optical component to its initial position and
orientation by locally allowing movement of particular flexures
along particular degrees of freedom without permanent deformations
of the flexures (e.g., the flexures largely moving within their
elastic regions) or deforming stresses on supported or aligned
other components.
[0058] In some optical systems, such as those including at least
two optical components, it is important that optical components are
properly aligned with each other or with other structures. This
need for alignment may be especially pronounced for high precision
applications. For example, some high precision optical systems
require that deviations in alignment between optical components be
no higher than a number of microns or smaller (e.g., at sub-micron
scale) so that the optical system maintains the appropriate
precision and accuracy. Thus, it may be imperative that these (and
other) optical systems are properly aligned and are secured to
remain that way. In some cases, however, manufacturing deviations
(e.g., the optical axes of optical components, the size, shape,
etc., of other mechanical components) are enough to exceed desired
alignment accuracy.
[0059] In some configurations, flexure arrangements with optical
components coupled thereto can be reoriented during assembly to
align the optical components, including as needed to compensate for
manufacturing variabilities (e.g., as noted above). For example,
optical components, including lenses, mirrors or other reflectors,
projection targets, image sensors, and others, can be aligned by
adjusting a flexure arrangement to which the components are coupled
to effectively cancel any manufacturing variability and otherwise
properly align the optical components.
[0060] However, there is room to improve conventional flexure
arrangements relative to adjusting and maintaining desired
alignment requirements (e.g., sub-micron alignment for high
precision optical applications). For example, screws or clamps that
couple a flexure to another component in some conventional
arrangements can impose a number of problems. For example, screws
and clamps may be prone to wear over time, which can allow the
optical components to move out of alignment. As another example,
particularly for threaded fasteners (e.g., screws), the adjustments
made by adjusting the fasteners may not be fine or easily
controllable enough to allow the orientation change needed to bring
the optical components into proper alignment. Further, the
tightening of a clamp or a screw (e.g., for final assembly) can
force optical components that have previously been aligned out of
proper alignment, which may then require realignment or other
corrections, or generally result in the inability to consistently
achieve desired alignment.
[0061] Some embodiments of the disclosure can address issues with
conventional flexure arrangements, including those noted above, by
providing improved systems and methods for flexure arrangements for
optical components. In particular, some embodiments can provide and
maintain proper alignment of optical components long after the
optical system is fully assembled (e.g., decreasing shifting of the
alignment over time). Similarly, some embodiments can prevent
undesirable shifting of the alignment of optical components during
and after assembly of an optical system.
[0062] In this regard, for example, some embodiments of the
disclosure can provide an optical system that includes a receiver
secured to a first optical component, and a flexure arrangement
secured to a second optical component. The flexure arrangement can
include a number of flexures (e.g., flexure arms) each of which is
received within a corresponding cavity of the receiver. The
cavities and the structure of the flexures can permit adjustments
of the orientation of the second optical component relative to the
first optical component so as to compensate for slight
misalignments (e.g., on the order of micrometers) of the optical
components (e.g., prior to assembly, such as manufacturing
variations). For example, clearances within the cavities can allow
corresponding flexures to be adjusted relative to multiple degrees
of freedom while received within the cavities, including so as to
adjust the overall system alignment along multiple (e.g., six)
degrees of freedom. Once in proper alignment, such as with the
second optical component adjusted via adjustment in orientation of
the flexures (e.g., by translating the flexures, etc.), the
cavities can be filled with an adhesive, which encapsulates a
portion (e.g., all) of a circumference of a given flexure (e.g.,
the circumference defined by a cross-section of the flexure). In
this way, once the adhesive has set, the proper alignment of the
optical components is maintained and is unlikely to change over
time. Further, there may be no risk of disturbing the desired
alignment while tightening mechanical fasteners (e.g., screws or
clamps) to secure the flexures in place. In some cases, this may be
particularly advantageous for high precision optical systems.
[0063] FIG. 1 shows a schematic illustration of an optical system
100, according to an embodiment of the disclosure. The optical
system 100 includes an optical component 102, a receiver 104, a
flexure arrangement 106, and an optical component 108. The optical
components 102, 108 can be implemented in various ways, and can
generally direct or receive light for a specific purpose. For
example, one or both of the optical components 102, 108 can be
lenses (or lens assemblies), imaging sensors (e.g., complementary
metal-oxide-semiconductor ("CMOS") sensors, charge coupled device
("CCD") sensors, projectors (e.g., digital or analog projectors),
optical filters, reflectors (or reflector assemblies), etc.
[0064] As shown, the optical component 102 is coupled (e.g.,
mechanically fastened, secured using adhesives, etc.) to the
receiver 104. Similarly, the optical component 108 is coupled to
the flexure arrangement 106 (e.g., the same or different ways as
the optical component 102). The receiver 104 includes cavities 110,
112 that can be implemented to embody any number of different
three-dimensional shapes. including rectangular-prism or otherwise
shaped pockets or slots. As used herein "pocket" refers to a cavity
that is configured to extend along each side of a relevant (e.g.,
cross-sectional) perimeter of a flexure or other body received in
the cavity. Some pockets may be formed as full pockets, with
cross-sectional perimeters configured to fully surround
corresponding perimeters of received flexures. Some pockets may be
formed as partial pockets, with cross-sectional perimeters
configured to extend only partly along one or more sides of a
corresponding perimeter of received flexures.
[0065] In some cases, the cavities 110, 112 can be defined within
respective protrusions that emanate from a surface of the receiver
104. For example, the receiver 104 can have a planar or other body
surface, where each protrusion emanates from the planar surface and
is substantially perpendicular (i.e., deviates from perpendicular
by less than 5 percent) to the receiver surface, although other
configurations (e.g., pyramidal protrusions) are possible.
Generally, however, the collective orientations of the protrusions
should be kinematic in nature, relative to the flexures to be
supported. In such a case, for example, the cavities 110, 112 can
be directed into the respective protrusion towards the receiver
surface with open ends that face away from the receiver surface. In
some configurations, the receiver 104 can have a bulk structure
with the cavities 110, 112 directed into the bulk structure (e.g.,
along planar or other body surface, absent protrusions). In some
embodiments, an insertion axis of the cavities 110, 112 (i.e., a
direction of insertion of a corresponding flexure) may extend in
parallel with a particular reference line, such as an optical axis
of an optical component to be supported.
[0066] In some cases, the cavities 110, 112 can be positioned (and
oriented) relative to an axis of the receiver 104 (e.g., a central
axis aligned with a relevant optical axis). For example, the
cavities 110, 112 can be positioned on opposing sides of the
receiver 104 relative to a particular axis. As another example,
such as with additional cavities (e.g., three cavities), the
cavities can be geometrically oriented relative to the axial axis
of the receiver 104 to generally follow various regular shapes
(e.g., an equilateral triangle, a regular pentagon, a regular
hexagon, etc.). In particular, central locations of each cavity can
define a vertex, and each vertex can define the regular (or other)
shape.
[0067] Although two cavities 110, 112 are shown, fewer or greater
numbers of cavities can be utilized. For example, three cavities
that collectively define an equilateral (or other) triangle can be
used. In some embodiments, the cavities of a receiver may all be
substantially similar to each other (e.g., deviating by less than
5% in shape and size). In some embodiments, insertion directions
for cavities of a receiver may be substantially parallel (i.e., may
deviate from parallel by less than 5%). In some embodiments, other
aspects of cavities of a receiver may not be oriented in parallel
with each other. For example, elongate directions of a particular
slot on a receiver may be oriented obliquely relative to elongate
directions of one or more neighboring or other slots on the
receiver.
[0068] In the illustrated, general example, the flexure arrangement
106 includes flexures 114, 116. The flexures 114, 116 can be
structured in different ways. In some cases, the flexures 114, 116
can be planar (i.e., can include substantially parallel opposing
sides that are substantially--i.e., 80% or more--wider than a
thickness of the flexure perpendicular to the sides), can have no
or a variety of different peripheral shapes (e.g., edge or central
cut outs), or exhibit other known flexure geometries. In different
embodiments, the flexures 114, 116 can be formed out of different
materials, including stainless steel, or beryllium copper alloy. In
some cases, flexures formed out of a beryllium copper can
beneficially provide a relatively high stiffness for the flexures
along the longitudinal axis of the flexure. Generally, the flexures
114, 116 can be relatively pliable relative to one or more degrees
of freedom (e.g., four degrees of freedom), while being relatively
stiff in the other degrees of freedom (e.g., the other two degrees
of freedom). The flexures 114, 116 correspond to the cavities 110,
112, respectively, and are configured to be received by and thereby
nest within the respective cavities 110, 112. In some cases, such
as when there are additional cavities, the flexures 114, 116 can be
interchangeably received within any of the cavities as appropriate
or a larger number of flexures can be provided. In some
embodiments, a particular flexure may be configured to be received
only in a particular cavity. Generally, the number of cavities
within the receiver 104 is greater than or equal to the number of
the flexures of the flexure arrangement 106, so that each flexure
can be received within a respective cavity.
[0069] Although there are two flexures 114, 116 shown, there can be
fewer or greater numbers of flexures within the flexure arrangement
106. For example, in some configurations, the flexure arrangement
106 has three flexures. In some embodiments, the flexures within
the flexure arrangement 106 are all substantially similar to each
other (e.g., deviating by less than 5% in shape and size). In some
embodiments, the flexures 114, 116 and corresponding cavities 110,
112 (or other flexures and cavities) can provide a kinematic
arrangement. For example, each flexure of an arrangement can
constrain a respective two degrees of freedom of the relative
orientation between optical components that are being aligned.
[0070] Because the flexure arrangement 106 supports the optical
component 108 and the receiver supports the optical component 102,
the position of each flexure 114, 116 within each respective cavity
110, 112 can determine the assembled orientation and position of
the optical component 102 relative to the optical component 108.
Correspondingly, in some embodiments, the cavities 110 can be sized
so that the flexures 114 can be adjusted within the cavities 110
relative to one or more (e.g., multiple) degrees of freedom. For
example, multiple dimensions of the cavities 110, 112 (e.g., as
measured in an associated cross-section) can be larger than
corresponding dimensions on the flexures 114, 116 (e.g., as
similarly measured). Further, a depth in an insertion direction of
the cavities 110, 112 can be larger than a minimum desired
insertion length of the flexures 114, 116 (i.e., a minimum length
by which the flexures 114, 116 should extend into the cavities 110,
112 for a final assembly). Thus, the flexures 114 116 can be
adjusted (e.g., translated) along appropriate degrees of freedom
after being nested within the cavities 110, 112 so that the
orientation and position of the optical component 108 relative to
the optical component 102 can be adjusted and aligned properly
(e.g., to compensate for deviations in manufacturing tolerances).
In some cases, an aligned orientation of the flexure arrangement
106 can have the flexures 114, 116 (and others) being bent along a
moveable degree of freedom of the respective flexure (e.g., bent in
a rotational direction that is about a respective bend line).
[0071] In different embodiments, different insertion lengths of
flexures relative to cavities can be employed. In some cases, to
provide appropriate bond area and overall stability, it may be
useful to ensure that a flexure extends into a cavity by at least a
minimum length. In some cases, a minimum length of one third of a
total length of a flexure can be used.
[0072] Once the flexures 114, 116 are in the desired position and,
correspondingly, the optical components 102, 108 are appropriately
aligned, adhesive 118, 120 can be introduced (e.g., injected) into
respective cavities 110, 112 and then cured to secure the flexures
114, 116 within the cavities 110, 112. In some cases, prior to
curing the adhesive 118, 120, the desired orientation and position
of the flexure arrangement 106 can be temporarily fixed, such as by
temporarily fixing the position and orientation of each flexure
with a UV-cured adhesive. In this way, for example, removal from
the adjusting manipulators (e.g., a robotic system that orients the
flexures 114, 116), as well as introduction, settling, or curing of
the adhesive 118, 120 can be ensured not to change the orientation
of the flexure arrangement.
[0073] As noted above, once the adhesive 118, 120 has been
introduced into the respective cavities 110, 112, the adhesive can
be cured to fix the position and orientation of the flexures 114,
116. The curing process can be implemented in different ways,
depending on the material composition of the adhesive 118, 120,
using a variety of known methods. For example, the adhesive 118,
120 can be implemented as light cured adhesives (e.g., ultraviolet
("UV") curved adhesives), thermal cured adhesives, dual cured
adhesives (e.g., thermal and UV cured adhesives), air cured
adhesives, humidity cured adhesives, etc.
[0074] Depending, for example, how the adhesive 118, 120 are
introduced into the respective cavities 110, 112, bonding
characteristics of the cured adhesive 118, 120 can vary. For
example, the cured bond can extend partially around a perimeter of
the flexure (e.g., at a cross-section perpendicular to an insertion
direction), or can extend around an entire perimeter of the
flexure.
[0075] In some embodiments, cavities can be configured with
features (e.g., internal profiles) that can help to better align or
secure flexures that are received therein. For example, as shown in
FIG. 1, an interior of the cavity 110 includes a well 122. In some
embodiments, the well 122 can receive the adhesive 118 and thereby
help to ensure that an appropriate bond line thickness to secure
the flexure 114 within the cavity 110 is obtained. Thus, for
example, it may be possible to obtain an appropriately thick bond
line regardless of the final position of the flexure 114 within the
cavity 110 after adjustment. As another example, a cavity can
include an interior recess (e.g., aligned with or separate from a
well) within which a flexure can rest once inserted into the
cavity.
[0076] In some embodiments, the strength of the adhesive, and the
total bond area (including the shape of the bond area) can be an
important factors that determine the stability of the overall
assembly. For example, for a given flexure (e.g., as selected based
on the desired stability properties of the optical system), the
bond area for the flexure should be sufficient to support the loads
of the optical system. In particular, in some cases, an aspect
ratio of a bond area should provide a ratio of 1 to 1, or in other
words, a substantially square shape (e.g., deviating by less than 5
percent), which can provide an optimal balance of inherent flexure
strength and strength of the adhesive bond.
[0077] A variety of specific configurations, including for cavity
and flexure geometry can be implemented, generally consistent with
the principles discussed above. In this regard, for example, FIGS.
2A and 2B show a schematic illustration of an assembly 130 that is
a specific example of the optical system 100 and includes a flexure
arrangement 132, and a receiver 134. The flexure arrangement 132
includes a flexure 136 (e.g., a planar flexure) that is received
within a cavity 138 defined in the receiver 134. A slot 140 is
directed along the receiver 134 in a direction defined by the
longitudinal extension of the flexure 136 (and, in this case, the
insertion direction of the flexure 136 into the cavity 138), which
further defines the cavity 138 and provides a partly open side
thereof. In the embodiment shown, the slot 140 is smaller in width
than the width of the flexure 136, so that the flexure 136 cannot
translate through the slot 140 and out of the cavity 138, although
other configurations are possible.
[0078] Interior walls of the receiver 134 that define the cavity
138 over a longitudinal extent of the flexure 136 extend entirely
along both sides that define a thickness of the flexure 136 (i.e.,
left and right sides in FIG. 2B), extend entirely along a distal
surface of a distal end of the flexure 136 (i.e., on a top side in
FIG. 2A), extend entirely along one side that defines a width of
the flexure 136 (i.e., on a bottom side in FIG. 2B), and extend
partially along an opposing side that also defines a width of the
flexure 136 (i.e., on a top side in FIG. 2A), as interrupted by the
slot 140. Thus, at least part of the cavity 138 provides a partial
pocket for the flexure 136. In some configurations, the slot 140
can provide an access location for the insertion of the adhesive
within the cavity 138 to secure the position and orientation of the
flexure 136 within the cavity 138, although other openings can be
used in other configurations.
[0079] FIGS. 2C and 2D show a schematic illustration of another
assembly 150 that is a specific example of the optical system 100
and includes a flexure arrangement 152, and a receiver 154. The
flexure arrangement 152 includes a flexure 156 that is received
within a cavity 158 defined in the receiver 154. Slots 160, 162 are
directed along the receiver 154 in a direction defined by the
longitudinal extension of the flexure 156 (and, in this case, in
the insertion direction of the flexure 156 into the cavity 158),
which further defines the cavity 158. In particular, the slots 160,
162 are positioned on opposing sides of the cavity 158, so that the
cavity 158 is defined by spaced-apart two portions 164, 166 of the
receiver 154. The portions 164, 166 are illustrated as being
u-shaped, however other shapes are contemplated. Similarly to the
slot 140 of the assembly 130, the slots 160, 162 are smaller in
width than the width of the flexure 156.
[0080] As shown, interior walls of the first portion 164 of the
receiver 154 that partially defines the cavity 158 over a
longitudinal extent of the flexure 156 extend entirely along a side
of the flexure 156 that defines a thickness of the flexure 156,
extend partially along one side of the flexure 156 that defines a
width of the flexure, extend partially along an opposing side of
the flexure 156 that defines the width of the flexure, and extend
partially along a distal surface of the distal end of the flexure
156 (obstructed from view in FIG. 2C) for a longitudinal extent of
the flexure 156. Similarly, walls of the second portion 166 of the
receiver 154 that partially defines the cavity 158 over a
longitudinal extent of the flexure 156 extend entirely along a side
of the flexure 156 that defines a thickness of the flexure 156,
extend partially along one side of the flexure 156 that defines the
width of the flexure, extend partially along an opposing side of
the flexure 156 that defines the width of the flexure, and extend
partially along a distal surface of the distal end of the flexure
156 (obstructed from view in FIG. 2C) for a longitudinal extent of
the flexure 136. Thus, the parts of the cavity 158 defined by the
portions 164, 166 individually and collectively provide a partial
pocket for the flexure 156. In some configurations, either of the
slots 160, 162 can provide an access location for the insertion of
the adhesive within the cavity 158 to secure the position and
orientation of the flexure 156 within the cavity 158, although
other openings can be used in other configurations.
[0081] FIGS. 2E and 2F show a schematic illustration of another
assembly 170 that is a specific example of the optical system 100
and includes a flexure arrangement 172, and a receiver 174. The
flexure arrangement 172 includes a flexure 176 that is received
within a cavity 178 defined in the receiver 174. As shown, the
cavity 178 of the receiver 174 fully encapsulates both sides that
define the width of the flexure 176, both sides that define the
thickness of the flexure 176, and a distal surface of a distal end
of the flexure 156 (obstructed from view in FIG. 2E) for a
longitudinal extent of the flexure 176. Thus, the cavity 178
defines a full pocket for the flexure 176.
[0082] In different embodiments, a cavity can be integrally formed
with a receiver or can be formed from multiple separate parts. In
this regard, for example, the cavity 178 is defined by two portions
180, 182 of the receiver 174 that are coupled to each other (e.g.,
using fasteners, adhesive, etc.), along the illustrated dashed line
of FIG. 2F. In alternative configurations, however, the portions
180, 182 can be integrally formed or more than two portions can be
used. Internal to the two portions 180, 182, the cavity 178 is
defined by respective recesses 184, 186 in the respective portions
180, 182 of the receiver 174. The recesses 184, 186 are further
defined by and include respective wells 188, 190 that are
illustrated as angled cuts into walls of the respective portions
180, 182, however the wells 188, 190 can embody other shapes or
cuts or may exhibit other dimensions (e.g., widths relative to the
recesses 184, 186). In some cases, the width of either or both of
the wells 188, 190 can be smaller than a width of the flexure 176.
In this way, the flexure 176 cannot be received within the wells
188, 190, and thus adhesive introduced into the cavity 178 can flow
into the wells 188, 190 to provide a minimum bond thickness (e.g.,
minimum bond line) between the receiver 174 and the flexure 176
when the adhesive is cured (e.g., corresponding to a depth of the
wells 188, 190).
[0083] FIGS. 2G and 2H show a schematic illustration of another
assembly 200 that is a specific example of the optical system 100
and includes a flexure arrangement 202, and a receiver 204. The
flexure arrangement 202 includes a flexure 206 that is received
within a cavity 208 defined in the receiver 204. As shown, for a
longitudinal extent of the flexure 206, the cavity 208 of the
receiver 204 extends fully along both sides that define a thickness
of the flexure 206, and one side that defines a width of the
flexure 206. Thus, the cavity 208 provides a slot with at least two
open sides to receive the flexure 206. Although, as illustrated,
the cavity 208 extends through the entire longitudinal dimension of
the receiver 204, in alternative configurations the cavity 208 can
extend partially through the longitudinal dimension of the receiver
204. In such a configuration, the cavity 208 can then, for example,
encapsulate an entire distal surface of a distal end of the flexure
206. Similarly to the cavity 178, the cavity 208 includes and is
further defined by a well 210 that can be implemented in a similar
manner as the wells 188, 190 of the receiver 174. As shown, a
longitudinal surface of the flexure 206 is exposed to the ambient
environment (e.g., prior to introduction of the adhesive. In this
way, the cavity 208 provides relatively easy access to receive the
adhesive.
[0084] In some embodiments, the configurations of FIGS. 2A-2H can
be advantageous in that the adhesive can be introduced into the
respective cavity in a variety of ways. For example, in some
configurations, adhesive can be introduced from the top, along the
plane defined by the flexures, etc. In some embodiments, the
configurations of FIGS. 2B, 2D, and 2F can be advantageous because
the adhesive bond can be loaded in shear (i.e., in the major plane
of the relevant cavity) rather than in tension or "peel."
[0085] In some embodiments, a cavity arrangement as generally
discussed above can be used to secure a flexure to multiple
components. For example, a flexure can be secured to a receiver as
well as within a larger flexure arrangement by being received and
then bonded within corresponding cavities on each of the two or
more structures. Correspondingly, although the flexures of FIGS.
2A-2H are not shown as being secured with cavities and adhesive to
the respective flexure arrangement, in some configurations these
(or other) flexures can be coupled to the corresponding flexure
arrangement (or other component) using similar features and
components as the previously described cavities and adhesives.
Further, it will be understood that the cavities and other features
of FIGS. 2A-2H (like others presented herein) are examples only and
that certain features of any one of the embodiments (e.g., open
sides, slotted or non-slotted features, wells, etc.) can be added
to or substituted into any of the other embodiments.
[0086] FIGS. 3-5 show an example of an optical system 300 that is a
specific example of the optical system 100 according to an
embodiment of the disclosure. The optical system 300 includes a
first receiver 302, a second receiver 304, an optical component
306, and a flexure arrangement 308. The first receiver 302 is
illustrated as being cylindrical in shape, and can be coupled to a
second optical component (not shown), including through a secured
connection to a frame of an imaging device with an imaging sensor.
The first receiver 302 includes cavities 312, 314, 316 that are
extend into an interior peripheral surface 318 of the first
receiver 302. In particular, each cavity 312, 314, 316 is directed
into the peripheral surface 318 of the first receiver 302 at an
oblique angle relative to the peripheral surface 318 at the
respective cavity 312, 314, 316 or relative to a radial reference
line at the same location, although other configurations are
possible. Similarly to the optical system 100, the cavities 312,
314, 316 are oriented around to a central axis of the first
receiver 302 so that ends of each cavity 312, 314, 316 that define
a vertex, where the vertices collectively (relative to the central
axis) define a regular shapes. In this case, these vertices of the
cavities 312, 314, 316 form an equilateral triangle, although other
shapes, including those with more or fewer cavities, are
contemplated.
[0087] Each of the cavities 312, 314, 316 is primarily formed as a
respective slot 320, 322, 324, each of which extends through the
peripheral surface 318 in a substantially straight direction and
stops prior to advancing through the exterior peripheral surface
326 of the first receiver 302. Each of the cavities 312, 314, 316
also include a respective well, formed as a bore 328, 330, 332 that
intersects and extends through the respective slot 320, 322, 324.
In particular, each of the bores 328, 330, 332 is positioned
between respective ends of the respective slots 320, 322, 324 so
that the boundaries defined by each of the bores 328, 330, 332
extend beyond the boundaries defined by the slots 320, 322, 324.
Further, the width of each of the bores 328, 330, 332 is greater
than the width of the corresponding slots 320, 322, 324 (e.g.,
relative to the top view of the optical system 300).
Correspondingly, each of the bores 328, 330, 332, which are
illustrated as cylinders but could be otherwise configured, thus
define opposing circular cutouts on opposing sides of the
respective slots 320, 322, 324.
[0088] Although the cavities 312, 314, 316, the slots 320, 322,
324, and the bores 328, 330, 332 extend entirely axially and fully
through the first receiver 302 (e.g., relative to an optical axis
of the optical component 306, and a central axis of the optical
system 300 generally), in alternative configurations some or all of
these can extend in other directions or can extend only partially
through the first receiver 302. Correspondingly, in some cases,
each (or some) of the cavities 312, 314, 316 can be formed as
pockets, access to which may only be possible through the
peripheral surface 318 of the first receiver 302.
[0089] The second receiver 304 is also illustrated as being
circular, and is coaxially positioned relative to the first
receiver 302 so that the second receiver 304 is nested within
(e.g., concentric with) the first receiver 302, although other
shapes or orientations are possible. The optical component 306 is
coupled to the second receiver 304 and is also coaxially positioned
relative to the second receiver 304. Although the optical component
306 is nested within the second receiver 304, in other
configurations, the optical component 306 can be otherwise oriented
relative to the second receiver 304. The optical component 306 is
illustrated as being a lens, but other optical components can be
used as appropriate. The second receiver 304 also includes cavities
334, 336, 338 that are directed into an exterior peripheral surface
341 of the second receiver 304. Similarly to the cavities of the
first receiver 302, each cavity 334, 336, 338 is directed into the
peripheral surface 341 of the second receiver 302 at an oblique
angle relative to the peripheral surface 341 at the respective
cavity 334, 336, 338 or relative to a radial reference line at the
same location, although other configurations are possible.
[0090] Each cavity 334, 336, 338 is primarily formed as a
respective slot 340, 342, 346, each of which extends through the
peripheral surface 341 in a substantially straight direction and
does not extend through the interior peripheral surface of the
second receiver 304 (e.g., to intersect the optical component 306).
Each cavity 334, 336, 338 also includes a respective well, formed
as a bore 348, 350, 352 that extends through the respective slot
340, 342, 346 in a similar manner as the bores 328, 330, 332 of the
first receiver 302. However, in contrast to the bores 328, 330,
332, each bore 348, 350, 352 is positioned at the end of a
respective slot 340, 342, 346 so that the end of each cavity 334,
336, 338 takes the boundary profile of the respective bore 348,
350, 352 (e.g., rather than the substantially straight slot). The
bores 348, 350, 352 are illustrated as being cylindrical, but
similarly to the bores 328, 330, 332, the bores 348, 350, 352 can
take other shapes. In some embodiments, including as shown, the
diameter of the bores 348, 350, 352 are greater than the widths of
the respective slots 340, 342, 346.
[0091] Although the cavities 334, 336, 338, the slots 340, 342,
346, and the bores 348, 350, 352 extend entirely axially and fully
through the second receiver 304 (e.g., relative to an optical axis
of the optical component 306, and a central axis of the optical
system 300 generally), in alternative configurations some or all of
these can extend in other directions or can extend only partially
through the second receiver 304. Correspondingly, in some cases,
each (or some) of the cavities 334, 336, 338 can be formed as
pockets, access to which may only be possible through the
peripheral surface 341 of the second receiver 304. Although each
end of each of the flexures 354, 356, 358 is described as being
received in a corresponding cavity of each receiver, in other
configurations, particular ends of one or more of the flexures 354,
356, 358 can be monolithic with the respective receiver. For
example, in one configuration, one or more ends of one or more of
the flexures 354, 356, 358 that is illustrated as nested within the
respective cavities 312, 314, 316 can instead be monolithic (or
otherwise fixed, such as with fasteners) with the first receiver
302. As another example, in a second configuration, one or more
ends of one or more of the flexures 354, 356, 358 that is
illustrated as nested within the respective cavities 334, 336, 338
can instead be monolithic or otherwise fixed, such as with
fasteners) with the second receiver 304.
[0092] As shown, each of the cavities 334, 336, 338 of the second
receiver 304 are in linear alignment with respective cavities 312,
314, 316 of the first receiver 302 in the assembled orientation. In
other configurations, the cavities 334, 336, 338 can be otherwise
aligned with the respective cavities 312, 314, 316 (e.g., after
repositioning and reorientation of either of the receivers 302,
304).
[0093] The flexure arrangement 308 includes flexures 354, 356, 358,
which are illustrated as being planar and rectangular, although
other configurations are possible. The flexures 354, 356, 358 are
substantially similar to each other (e.g., having a substantially
similar shape and size). Each flexure 354, 356, 358 is positioned
within a set of the aligned cavities 312, 334, 314, 336, or 316,
338 in the separate receivers 302, 304. In particular, one end of
the flexure 354 is positioned within the cavity 312 and the
opposing end of the flexure 354 is positioned within the cavity
334. Similarly, one end of the flexure 356 is positioned within the
cavity 314 and the opposing end of the flexure 356 is positioned
within the cavity 336. Additionally, one end of the flexure 358 is
positioned within the cavity 316 and the opposing end of the
flexure 358 is positioned within the cavity 338.
[0094] Consistent with the general discussion above, the cavities
312, 314, 316, 334, 336, 338 of the receivers 302, 304 are sized to
allow the flexures 354, 356, 358 to be adjusted therein in multiple
degrees of freedom. In particular, for the illustrated example, a
thickness of each of the cavities 312, 314, 316, 334, 336, 338 is
some dimensions of the cavities 312, 314, 316, 334, 336, 338 of the
receivers 302, 304 are substantially larger (i.e., 25% or more
larger, e.g., 30% or 50% larger) than the corresponding thickness
of the flexures 354, 356, 358. For example, a depth of each of the
cavities 312, 314, 316, 334, 336, 338 in an insertion direction is
larger (e.g., at least 10% larger) than a target (i.e., optimal or
intended) insertion length of the corresponding flexures 354, 356,
358. Correspondingly, for example, the length defined between an
inner end of one cavity and an inner end of another cavity (e.g.,
between the blind end of the slot 320 and the opposing side of the
bore 348) is substantially larger than the length of the flexure
(e.g., the flexure 354). As another example, the thickness of each
cavity (e.g., the thickness of the cavities 312, 334) is
substantially larger than the thickness of the corresponding
flexure (e.g., the flexure 354). As yet another example, the
constrained axial height of the cavities is substantially larger
(in this case non-existent, due to the axially open-ended
configuration) than the axial height of the flexure.
[0095] Individually and collectively, these dimensional
relationships allow for the flexures 354, 356, 358 to be adjusted
within the cavities 312, 314, 316, 334, 336, 338, including, for
example, by being translated axially, translated along the length
of the flexures (or cavities), translated along the width of the
cavities, deflected (or rotated) about the axial axis, pivoted
about the axis defined by the length of the flexures, or pivoted
into or out of the page with respect to the top or bottom view.
Thus, each of these flexures 354, 356, 358 can be adjusted relative
to multiple degrees of freedom and alignment of the assembly as a
whole can be adjusted, at least somewhat, along multiple degrees of
freedom (e.g., six degrees of freedom). As such, the alignment of
the receivers 302, 304 can be adjusted via the flexures 354, 356,
358 to compensate for manufacturing deviations. Thus, the optical
component 306 and an optical component that can be coupled to the
first receiver 302 can be properly aligned.
[0096] Once the receivers 302, 304 have been aligned as desired,
the orientation and the position of the flexures 354, 356, 358 can
be fixed with adhesive that is introduced into the cavities 312,
314, 316, 334, 336, 338. In some cases, as generally discussed
above, the flexures 354, 356, 358 can first be temporarily fixed
(e.g., with light-cured adhesive And then adhesive can be cured
within each of the cavities 312, 314, 316, 334, 336, 338 to
maintain the desired aligned position of the receivers 302, 304
(and associated optical components).
[0097] FIGS. 6-13 show an example of an optical system 400 that is
a specific example of the optical system 100 according to an
embodiment of the disclosure. The optical system 400 includes a
first optical assembly 402, a flexure arrangement 404, a second
optical assembly 406, and a receiver 408. The first optical
assembly 402 includes a housing 409 and a first optical component
411, which is implemented in the illustrated embodiment as a lens
(although other optical components could be utilized or
substituted). The first optical assembly 402 (and the first optical
component 411) is coupled to the receiver 408 using one or more
fasteners (not shown) that can threadingly engage the first optical
assembly 402 and the receiver 408. In other cases, the optical
assembly 402 can be coupled to the receiver 408 in other ways
(e.g., via ultrasonic welding, adhesives, etc.), or the optical
assembly 402 and the receiver 408 can be integrally formed.
[0098] The flexure arrangement 404 is formed as an extension of the
second optical assembly 406 and includes flexures 410, 412, 414, a
plate 416, and fasteners 420, 422 (and one or more others, not
shown). The flexures 410, 412, 414 are substantially similar to
each other (e.g., substantially similar in shape and size), are
planar, and extend substantially perpendicularly from the plate
416. Similarly to the configurations discussed above, a central
location of each flexure 410, 412, 414 defines a vertex, such that
when viewed from a top view, the connected vertices define an
equilateral triangle (e.g., each of the flexures 410, 412, 414 is
offset sixty degrees relative to adjacent flexures), although other
configurations are also possible. The fasteners 420, 422 (and
corresponding holes that receive the respective fasteners) are
positioned behind the respective flexures 410, 412, 414 and
threadingly engage a support block 424 of the second optical
assembly 406 to couple the flexure arrangement to the second
optical assembly 406.
[0099] The second optical assembly 406 includes the support block
424, a printed circuit board 426, and a second optical component
428. The second optical component 428 is implemented as an image
sensor that is affixed and integrated with the printed circuit
board 426, although other optical components could be utilized and
substituted accordingly. The support block 424 is illustrated as
having a substantially J-shape, with the plate 416 of the flexure
arrangement 404 coupled to an angled surface of the support block
424, although a variety of shapes are contemplated including
rectangular blocks and other support structures.
[0100] As shown in FIGS. 6 and 7 in particular, the receiver 408
includes protrusions configured as pocket blocks 430, 432, 434
(including block caps 450, 452, 454) extending substantially
perpendicularly from a receiver body 436, with fasteners 438, 440,
442, 444, 446, 448 that secure the block caps 450, 452, 454 in
place. In particular, the fasteners 438, 440 threadingly engage the
pocket block 430 and the block cap 450 to couple these components
together. Similarly, the fasteners 442, 444 threadingly engage the
pocket block 432 and the block cap 452 to couple these components
together. Additionally, the fasteners 446, 448 threadingly engage
the pocket block 434 and the block cap 454 to couple these
components together.
[0101] Each pocket block 430, 432, 434, including the corresponding
block cap 450, 452, 454 defines a corresponding pocket, which will
be described in more detail below. In some cases, rather than being
formed from multiple pieces, a pocket block or other protrusion can
be integrally formed with the receiver body 436. Further, although
base portions of the pocket blocks 430, 432, 434, to which the
block caps 450, 452, 454 are secured, are shown as being integrally
formed with the receiver body 436, in other configurations, pocket
blocks can be formed entirely separately from a receiver body and
then coupled thereto.
[0102] As shown in particular in the assembled configuration of
FIG. 6, a free end of each flexure 410, 412, 414 (e.g., the end of
each flexure opposite the plate 416) is received within a
respective pocket defined by each pair of a pocket block and a
block cap. In particular, the pocket block 430 defines a pocket
456, the pocket block 432 defines a pocket 458, and the pocket
block 434 and the block cap 454 defines a pocket 460. Although a
variety of pocket or other cavity configurations are possible
(e.g., as discussed above), the geometry of each pocket 456, 458,
460 is at least partially determined internal recesses of the
respective blocks that define the particular pocket, which will be
described in more detail below. In the assembled configuration, the
free end of the flexure 410 is received within the pocket 456, the
free end of the flexure 412 is received within the pocket 458, and
the free end of the flexure 414 is received within the pocket
460.
[0103] To assist with introduction of adhesive during assembly,
each pocket block 430, 432, 434 includes multiple openings formed
as an injection port and a viewing port, respectively, in fluid
communication with the respective pocket 456, 458, 460. In other
cases, one or both of an injection port or a viewing port can be
directed through another surface (e.g., upper surface of the
receiver body 436, or otherwise). In the illustrated example, as
shown in FIG. 7 in particular, an injection port 462 and a viewing
port 464 are both directed into the surface of the pocket block 432
opposite the block cap 452 (see FIG. 6), and both in fluid
communication with the pocket 458. In some embodiments, the
injection port 462 can receive an adhesive dispenser (not shown),
such as a needle, a syringe, etc., to introduce the adhesive into
the pocket 458 via the injection port 462. The viewing port 464
can, after the adhesive has been introduced into the pocket 458, be
used to ensure (e.g., via visual inspection by a user) that the
adhesive has dispersed or cured properly. For example, adhesive can
be introduced into the pocket 458 until the adhesive oozes out of
(or is visible within) the viewing port 464. This can provide a
clear visual indication (e.g., to a user) that enough adhesive has
been dispensed to fill the entire pocket 458 with adhesive. In some
cases, without this visual identification, a respective pocket can
be easily under-loaded with adhesive, which can provide an
undesirable adhesive bond. In some embodiments, additional or
alternative injection ports can be alternatively oriented (e.g., as
shown for an opening 466 in FIG. 7). In some embodiments, an open
end of a cavity, including an open end through which a flexure is
received, can provide an opening for introduction or visual
inspection of adhesive.
[0104] FIG. 8 shows a cross-sectional view of the pocket 458 with
the flexure 412 therein taken along line 8-8 of FIG. 7. As shown,
the dimensions of the flexure 412 are substantially smaller than
the dimensions of the pocket 458, which allows the flexure 412 to
be adjusted relative to multiple degrees of freedom (e.g.,
translated and rotated) to align the optical assemblies 402, 406
(see FIG. 6). For example, a thickness 468 of the pocket 458
perpendicular to an insertion direction is substantially larger
(e.g., at least 50% larger) than a thickness 470 of the flexure
412. As another example, a width 472 of the pocket 458 is
substantially larger than a width 474 of the flexure 412.
[0105] FIG. 8 also shows the spatial relationship between the
injection port 462 and an opening 476 directed through the flexure
412 proximate the free end thereof. As shown, the injection port
462 is in alignment with the opening 476. Accordingly, when
adhesive is injected into the pocket 458 via the injection port
462, the adhesive can readily flow through the opening 476 to
disperse on the opposing side of the flexure 412 (e.g., the side of
the flexure 412 that does not face the injection port 462.
[0106] FIG. 9 shows another cross-sectional view of the pocket 458
with the flexure 412 therein, taken along line 9-9 of FIG. 7. As
shown, the length 482 of the pocket 458 in the insertion direction
is sized to be substantially larger (e.g., at least 25% larger)
than an insertion depth 483 for the flexure 412, so that the
flexure 412 can be translated relative to a degree of freedom
corresponding to a direction that is defined by the length 482 of
the pocket 458. This further supports a high degree of
adjustability of the flexure 412 (and other similar flexures) while
also helping to ensure that the flexure 412 can remain sufficiently
inserted into the pocket 458 to provide appropriate bond area for
the adhesive.
[0107] FIG. 9 also shows, in an alternative configuration indicated
by a dotted-line outline, the flexure 412 being bent with the free
end of the flexure 412 contacting an inner surface of the block cap
452. In particular, the flexure 412 is shown as having been bent or
pivoted about the bend at the opposing end of the flexure 412
(e.g., the end in close proximity to the plate 416), although a
variety of other deformations are also possible. This bending of
the flexure 412 can also correspondingly cause the other flexures
410, 414 to bend to accommodate the movement of the flexure 412.
Thus, in an aligned (i.e., adjusted) position of the flexure
arrangement 404, each flexure 410, 412, 414 can sometimes be bent
to various degrees relative to a starting configuration (e.g., at a
bent joint with a support plate). Generally, due y to the
relatively large size of the pockets 456, 458, 460, even with one
or more of the flexures 410, 412, 414 in a bent configuration, the
amount of adhesive on opposing longitudinal surfaces of each
flexure may be substantially the same (e.g., deviating by less than
5 percent). In this way, as further enhanced in some cases by the
inclusion of an adhesive well (as also discussed below), the
flexures 410, 412, 414, even in a bent configuration, can be
reliably and securely anchored in place once the adhesive has
cured.
[0108] In different embodiments, as generally discussed above,
flexures of a flexure arrangement can be configured in various ways
for attachment to an optical component. In this regard, for
example, FIG. 10 shows an exploded partial view of a sub-assembly
409 of the optical system 400, including the flexure arrangement
404 and the receiver 408. In the embodiment shown, the flexure
arrangement 404 further includes a flexure body 484 that is
integrally formed with the flexures 410, 412, 414 and includes an
aperture 486 that is centrally located on the body 484. The plate
416 also includes elongated slots 488, 490, 492 that are axially
directed through the entirety of the thickness of the plate 416,
and an aperture 494 that is also centrally located. Each of the
flexures 410, 412, 414 include respective free ends 496, 498, 500
opposite the flexure body 484, each having an opening 478, 476, 480
directed therethrough. As described above, the flexures 410, 412,
414 are planar, and each has a neck region of reduced width that
can allow for better flexibility (e.g., a neck region 502 of the
flexure 414).
[0109] The illustrated sub-assembly 409 of FIG. 10 can be assembled
by inserting the free end 496 of the flexure 410 through the slot
488, inserting the free end 498 of the flexure 412 through the slot
490, and inserting the free end 500 of the flexure 414 through the
slot 492. Once the flexures are inserted into the respective slots
of the plate 416, e.g., with the flexure body 484 abutting the
plate 416 so that the aperture 486 is aligned with the aperture
494, the plate 416 and the flexure body 484 can be coupled together
(and to other components), with fasteners or other features. In the
illustrated embodiment, as shown in FIG. 6, for example, the
apertures 486, 494 are aligned with an aperture of the support
block 424 of the optical assembly 406 so that light from the
optical assembly 406 can be received at the second optical
component 428.
[0110] In some embodiments, the plate 416 provides a connection
that stiffly secures the flexures 410, 412, 414 to the component
that supports the second optical component 428 (e.g., in a
clamp-like manner). For example, when the plate 416 secures the
flexure body 484 to the optical component 428, when assembled, the
bent ends of each flexure 410, 412, 414 are secured in close
proximity to edges of the respective slots 488, 490, 492 of the
plate 416. Further, each of the flexures 410, 412, 414 have a
rather small bend radius at the bend near the slots 488, 490, 492,
and each inner edge of each slot 488, 490, 492 in the plate 416 is
placed as close as possible to each bend radius of each
corresponding flexure. Accordingly, the flexure arrangement 404 as
a whole may be prevented from bending to allow the flexures 410,
412, 414 to extend longitudinally (e.g., along the longitudinal
extent of the particular flexure). In some embodiments, each
internal edge of each slot 488, 490, 492 can be substantially
parallel to each corresponding flexure 410, 412, 414.
[0111] Although the slots 488, 490, 492 are illustrated as being
closed (e.g., bounded by two sides) in other configurations the
outer edge of each slot 488, 490, 492 can be removed, or in other
words, each slot 488, 490, 492 can be an open-sided slot. For
example, the inner edge 493 of the slot 492 is positioned in close
proximity to the bend of the flexure 414 and can be the only edge
of the slot 492. In other configurations, other components can be
substituted for the plate 416, but can provide a similar structure
and function as the plate 416. For example, a washer (e.g., a round
or other washer) can be similarly interfaced with each flexure.
[0112] With the flexure arrangement 404 thus prepared, each of the
flexures 410, 412, 414 can then be received within the respective
pockets 456, 458, 460 as shown in FIG. 7. For example, the free end
496 of the flexure 410 is inserted into the pocket 456, the free
end 498 of the flexure 412 is inserted into the pocket 458, and the
free end 500 of the flexure 414 is inserted into the pocket
460.
[0113] The position and orientation of the flexures 410, 412, 414
can be adjusted within the respective pockets 456, 458, 460 as
described above (e.g., to compensate for manufacturing variability
and to compensate for deviations in optical component alignment).
Then, adhesive can be inserted into each of the pockets (e.g., via
a respective injection port) to fix the desired orientation and
position of the flexures 410, 412, 414 (e.g., once the adhesive has
cured). Notably, in this embodiment, similarly to other embodiments
discussed above, each of the flexures 410, 412, 414 are directly
coupled to the receiver 408 using only the adhesive received within
the pockets 456, 458, 460 and no other mechanical fastening
elements. For example, the flexures 410, 412, 414 are not directly
fastened to the receiver 408 using bolts, screws, clamps, etc.
Correspondingly, for example, as also discussed above, the act of
securing the flexures 410, 412, 414 in the desired alignment may
not introduce stresses that adversely affect the alignment, as can
occur, for example, with screws or clamps.
[0114] As also noted above, in some cases, the insertion depth of a
flexure within a given pocket can be at least a third of the length
of the given flexure (e.g., as measured for the flexure overall or
from an opposing anchor point of the flexure). In this way, an
appropriate strong mechanical interface is achieved. Additionally,
in some cases, each of the flexures can have a ratio of bond area
(e.g., the total area defined between the adhesive, a surface of
the flexure, and a surface of the walls that define the pocket) to
insertion depth for a flexure that is greater than a threshold
ratio.
[0115] As also noted above, certain features can be provided to
ensure appropriate bond line thickness or other beneficial results.
In this regard, for example, FIG. 12 shows the interior space of
the integrally formed portion of the pocket block 432, which is
similar to the corresponding interior space of the other pocket
blocks 430, 434. In particular, the pocket block 432 includes a
relatively flat surface that abuts against a surface of the block
cap 452 when assembled, and a well 504. The well 504 is in fluid
communication with both the injection port 462 and the viewing port
464. During assembly and thereafter, the well 504 provides a local
maxima depth region for the pocket 458 that can increase the
thickness of the bond between the pocket block 432 and the flexure
412 by defining a minimum possible bond line thickness (and, in
some cases, also a maximum bond line thickness). In the illustrated
example, the pocket block 432 also includes a chamfer 506 that is
angled toward the pocket 458, such as may assist in initial
insertion of a flexure.
[0116] Continuing, FIG. 13 shows the interior space of the block
cap 452, which is similar to the interior space of the other block
caps 450, 454. In particular, the block cap 452 includes a recess
508, a well 510 within the recess 508, and bores 512, 514, and a
chamfer 516 that is angled toward the pocket 458 and faces the
chamfer 506. The recess 508 further defines the boundaries of the
pocket 458 and is configured to receive a flexure nested therein.
The well 510, which has a width that is smaller than a width of the
flexure 412, is directed into the rear surface that defines the
recess 508. Similarly to the well 504, the well 510 advantageously
provides a minimum bond thickness for adhesive introduced into the
pocket 458 to secure the flexure 412. In particular, because the
flexure 412 is too wide to be received within the well 510 the well
510 can be filled with adhesive regardless of the position of the
flexure 412 (e.g., particularly as fed via the aligned opening 476
and injection port 462, as shown in FIG. 9). Accordingly, even when
the flexure 412 is abutted against the interior surface of the
block cap 452 adjacent the well 510, adhesive within the well 510
can provide a minimum bond thickness defined by the depth of the
well 510.
[0117] In some embodiments, as generally noted above, a well can be
aligned with other openings to more easily receive adhesive during
assembly. For example, referring again to FIG. 8, it can be seen
that the injection port 462, the opening 476, and the well 510 are
aligned along an injection axis defined by the injection port 462.
Accordingly, adhesive can easily flow from the injection port 462,
through the opening 476, and into the well 510, as well as to other
parts of the pocket 458. Thus, for example, even if the flexure 412
is adjusted to be flush against certain internal surfaces of the
pocket 458, a reliable flow of adhesive to satisfactorily fill the
pocket 458 (including the well 510) can be readily achieved.
[0118] In some of the embodiments above, including relative to the
systems 300, 400 adhesive is discussed but not expressly shown in
the corresponding figures to provide clearer views of other
components in the figures. Those of skill with the art will
recognize that liquid adhesive, for example, before hardening, may
fully or partially fill the spaces into which the adhesive is
introduced (e.g., within the various cavities of the systems 300,
400) depending on a variety of properties, including viscosity,
surface tension, surface compatibility, and so on, including as
schematically illustrated in FIGS. 2B, 2D, 2F, and 2H.
[0119] Consistent with the discussion above, some embodiments can
include methods of aligning optical components, including within
the various optical assemblies expressly discussed above. In this
regard, for example, FIG. 14 shows a flowchart of a process 600 for
assembling an optical system. At operation 602, the process 600 can
include inserting one or more flexures (e.g., each flexure) of a
flexure arrangement into a corresponding cavity of a receiver. In
some cases, one end of each flexure can be inserted into a cavity
of one receiver and the opposite end of each flexure can be
inserted into another cavity of a second receiver (e.g., as forms
part of a flexure assembly to be secured to the first
receiver).
[0120] At operation 604, the process 600 can include adjusting the
position and orientation of each flexure, when the flexures are
received within the respective cavities. By adjusting the position
and orientation of the flexure arrangement, the desired alignment
between optical components coupled to the receiver and the flexure
arrangement, respectively can be realized. In some embodiments, as
also discussed above, adjusting flexures can include adjusting
flexures relative to multiple degrees of freedom within the
corresponding cavities, including so as to adjust a larger optical
system relative to multiple (e.g., six) degrees of freedom. In some
cases, some or all of the flexures within the flexure arrangement
can be bent (e.g., pivoted) relative to a base structure, which can
sometimes result in each flexure contacting only one longitudinal
surface of the respective cavity. In some embodiments, a robotic or
other automated system can be used to appropriately align the
relevant components. For example, a manipulator (e.g., of a robot
arm) can hold and orient the flexure arrangement to move the
arrangement to a properly aligned orientation.
[0121] At operation 606, the process 600 can include temporarily
fixing the desired position of each flexure of the flexure
arrangement. For example, a droplet or bead of light cure adhesive
can be placed on an external surface of the flexure (e.g., along a
chamfer at an entrance to a pocket or other cavity, as may provide
enhanced surface area), and the light-cured appropriately to
temporarily fix the desired position of each flexure. In some
embodiments, such temporary fixing of a flexure may not be
performed or may not be performed for all flexures. In different
embodiments, temporarily fixing a flexure may be performed before
or after introducing a main charge of adhesive for permanent fixing
of the flexure(s). In some embodiments, temporarily fixing the
desired position of each flexure can occur with a manipulator
holding the flexure arrangement in the desired orientation.
[0122] At operation 608, the process 600 can include introducing
adhesive into each cavity of the receiver that is associated with a
flexure, with the flexures received within the respective cavities.
In some cases, the adhesive can be introduced into each cavity via
an injection port or other opening that is separate from an
insertion opening through which the flexure is introduced into the
cavity. Additionally, in some cases, adhesive can be introduced
into the cavity (e.g., via an injection port) until adhesive oozes
out of (or is visible within) a viewing port that is in fluid
communication with the cavity. In different embodiments, as alluded
to above, adhesive can be introduced into a cavity at operation 608
before or after a flexure is temporarily fixed in place, as
applicable.
[0123] At operation 610, process 600 can include curing the
adhesive with the flexures received in the respective cavities and
in the desired orientation and position (e.g., the collective
aligned orientation). Any variety of known methods for known
adhesives can be used at operation 610 to secure the flexures in
the appropriate alignment. In some embodiments, adhesive can be
cured after the assembly has been removed from an alignment system
(e.g., a robotic system), such as after a temporary fixing of the
flexures under operation 606 has been completed. Thus, for example,
the alignment system can be used for other assemblies even as the
main charge of adhesive cures, thereby generally improving
manufacturing throughput.
[0124] In some embodiments, process 600 can include removing a
flexure arrangement from a manipulator (e.g., of a robotic system)
after adhesive is applied. For example, after the desired
orientation is temporarily fixed (e.g., as discussed above), the
flexure arrangement can be removed from a manipulator for easier
introduction of a main charge of adhesive into the cavities, and
for curing of the introduced adhesive (e.g., introducing the
flexure arrangement in the desired orientation and with adhesive
within the cavities into an oven for curing the adhesive). This may
be useful, for example, in order to provide more rapid through-put
during manufacturing, by freeing a manipulator for alignment of
additional flexure arrangements even as adhesive of a
previously-aligned arrangement is still curing. In other
embodiments, however, other approaches are possible. For example, a
flexure arrangement can be removed from a manipulator after a main
charge of adhesive has been introduced, but before the main charge
has cured, or a flexure arrangement can be removed from a
manipulator after a main charge of adhesive has partly or fully
cured.
[0125] Thus, the disclosed embodiments provide improved flexure
arrangements and associated methods for securing and aligning
optical components. For example, some of the flexure arrangements
for optical components and methods described above can
advantageously improve the assembly and maintenance of the
alignment of optical components, especially for high precision
applications, including by reducing the adverse effects on
alignment of conventional approaches to secure the flexures in
place.
[0126] The previous description of the disclosed embodiments is
provided to enable any person skilled in the art to make or use the
systems and methods of the disclosure. Various modifications to
these embodiments will be readily apparent to those skilled in the
art, and the generic principles defined herein may be applied to
other embodiments without departing from the spirit or scope of the
disclosure. Thus, the disclosure is not intended to be limited to
the embodiments shown herein but is to be accorded the widest scope
consistent with the principles and novel features disclosed
herein.
* * * * *